U.S. patent number 10,668,414 [Application Number 15/327,834] was granted by the patent office on 2020-06-02 for intake bypass flow management systems and methods.
This patent grant is currently assigned to CUMMINS FILTRATION IP, INC.. The grantee listed for this patent is Cummins Filtration IP, Inc.. Invention is credited to W. Beale Delano, Andry Lesmana, Dane P. Miller, Shantanu Nadgir, Jeffrey L. Oakes, Jitesh Panicker, Yashpal Subedi, Barry M. Verdegan.
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United States Patent |
10,668,414 |
Subedi , et al. |
June 2, 2020 |
Intake bypass flow management systems and methods
Abstract
Filtration systems having a normal filtration mode and an
enhanced filtration mode are described. In some arrangements, the
filtration system is an air filtration system having a primary air
filter element, a pre-cleaner, and a pre-cleaner bypass valve.
Based on feedback from an intake air quality sensor the bypass
valve is either opened or closed to selectively route intake air
through the pre-cleaner during sensed dirty air operating
conditions (e.g., heavy dust or moisture concentrations). In other
arrangements, the filtration system is a liquid filtration system
(e.g., a fuel or oil a secondary filter. The filtration system
selectively routes the liquid being filtered through the main
filter, the secondary filter, or a combination thereof depending on
a detected event or sensed characteristic of the liquid.
Inventors: |
Subedi; Yashpal (Madison,
WI), Miller; Dane P. (Monona, WI), Verdegan; Barry M.
(Stoughton, WI), Nadgir; Shantanu (Columbus, IN), Delano;
W. Beale (Columbus, IN), Lesmana; Andry (Columbus,
IN), Panicker; Jitesh (Columbus, IN), Oakes; Jeffrey
L. (Columbus, IN) |
Applicant: |
Name |
City |
State |
Country |
Type |
Cummins Filtration IP, Inc. |
Columbus |
IN |
US |
|
|
Assignee: |
CUMMINS FILTRATION IP, INC.
(Columbus, IN)
|
Family
ID: |
55163653 |
Appl.
No.: |
15/327,834 |
Filed: |
July 21, 2015 |
PCT
Filed: |
July 21, 2015 |
PCT No.: |
PCT/US2015/041395 |
371(c)(1),(2),(4) Date: |
January 20, 2017 |
PCT
Pub. No.: |
WO2016/014580 |
PCT
Pub. Date: |
January 28, 2016 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20170203241 A1 |
Jul 20, 2017 |
|
Related U.S. Patent Documents
|
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|
|
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
62027984 |
Jul 23, 2014 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01D
29/56 (20130101); B01D 35/005 (20130101); B01D
46/0087 (20130101); F02M 35/024 (20130101); F02M
35/0212 (20130101); B01D 35/147 (20130101); B01D
46/46 (20130101); B01D 29/605 (20130101); B01D
35/26 (20130101); F02M 35/082 (20130101); B01D
46/442 (20130101); B01D 2279/60 (20130101) |
Current International
Class: |
B01D
53/22 (20060101); B01D 35/00 (20060101); B01D
29/60 (20060101); B01D 29/56 (20060101); B01D
46/46 (20060101); B01D 46/44 (20060101); B01D
35/147 (20060101); F02M 35/08 (20060101); B01D
46/00 (20060101); B01D 35/26 (20060101); F02M
35/02 (20060101); F02M 35/024 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
Harris "HowStuffWorks _How Superchargers Work" Mar. 29, 2013, 11
pages
<https://web.archive.org/web/20130329080120/https://auto.howstuffworks-
.com/supercharger.htm/printable (Year: 2013). cited by examiner
.
First Office Action issued for Chinese Patent Application No.
2015800386264, dated Jun. 5, 2018, 6 pages. cited by applicant
.
Dust Sensor Module, P/N: DSM 501, Specification, Samyoung S&C
Co., Ltd. 11 pages, www.samyoungsnc.com,
www.samyoungsnc.com/products/3-1%20Specification%20DSM501.pdf, no
date given, but at least as early as Jul. 21, 2014. cited by
applicant .
GP2Y101AY0F, Compact Optical the Sensor, Device Specification Sheet
No. E4-A01501EN, Sharp Corporation, Dec. 1, 2006, 9 pages. cited by
applicant .
International Search Report and Written Opinion issued for PCT
Application No. PCT/US2015/041395, dated Dec. 17, 2015, 10 Pages.
cited by applicant.
|
Primary Examiner: Shumate; Anthony R
Attorney, Agent or Firm: Foley & Lardner LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Stage of PCT Application No.
PCT/US2015/041395, filed Jul. 21, 2015, which claims priority to
U.S. Provisional Patent Application No. 62/027,984, entitled "AIR
INTAKE BYPASS FLOW MANAGEMENT SYSTEMS AND METHODS," filed on Jul.
23, 2014. The contents of both applications are herein incorporated
by reference in their entirety.
Claims
What is claimed is:
1. A filtration system comprising: a fluid source providing a fluid
to be filtered to a filtration line; a main filter; a secondary
filter positioned upstream of the main filter in a fluid flow
direction; a detector that detects a fill-up condition, a start-up
condition, a change in fluid contaminant concentration, or a fluid
flow rate change of a second system using the fluid; a valve
positioned upstream of the main filter and downstream of the
secondary filter in the fluid flow direction, the valve can be
opened or closed so as to switch the filtration system between a
normal filtration mode and an enhanced filtration mode, the normal
filtration mode corresponding to a first operating mode where fluid
to be filtered flows to the main filter through a first flow path
from the filtration line to a location downstream the main filter,
the enhanced filtration mode corresponding to a second operating
mode in which an increased amount of the fluid to be filtered is
filtered through the secondary filter element than when in the
normal filtration mode, the fluid to be filtered flows along a
second flow path from the filtration line through the secondary
filter prior to flowing to the main filter element, an electronic
control unit having a memory and a processor, the electronic
control unit configured to: receive a feedback signal from the
detector indicative of the fill-up event the start-up event, the
change in fluid contaminant concentration, or the fluid flow rate
change of the second system, and switch between the normal
filtration mode and the enhanced filtration mode in response to the
fill-up event, the start-up event, the change in fluid contaminant
concentration, or the fluid flow rate change.
2. The filtration system of claim 1, wherein when the filtration
system is in the normal filtration mode, no fluid to be filtered
flows through the secondary filter.
3. The filtration system of claim 1, wherein when the filtration
system is in the normal filtration mode, some fluid to be filtered
flows through the secondary filter.
4. The filtration system of claim 1, wherein the system using the
fluid is an internal combustion engine.
5. The filtration system of claim 1, wherein the system using the
fluid is a hydraulic system.
6. The filtration system of claim 1, further comprising a pump that
further induces fluid flow through the secondary filter.
7. A filtration system comprising: a fluid tank fluid source
providing a fluid to be filtered; a main filter; a secondary
filter; a detector that detects a fill-up condition, a start-up
condition, a change in fluid contaminant concentration, or a fluid
flow rate change of a second system using the fluid; a valve that
can be opened or closed so as to switch the filtration system
between a normal filtration mode and an enhanced filtration mode,
the enhanced filtration mode corresponding to an operating mode in
which an increased amount of the fluid to be filtered is filtered
through the secondary filter element than when in the normal
filtration mode; an electronic control unit having a memory and a
processor, the electronic control unit configured to: receive a
feedback signal from the detector indicative of the fill-up event,
the start-up event, the change in fluid contaminant concentration,
or the fluid flow rate change of the second system, and switch
between the normal filtration mode and the enhanced filtration mode
in response to the fill-up event, the start-up event, the change in
fluid contaminant concentration, or the fluid flow rate change,
wherein the fluid source is a fluid tank, and wherein the secondary
filter is part of a fluid recirculating loop that routes fluid that
passes through the secondary filter back to the fluid tank.
8. The filtration system of claim 7, wherein the detector further
detects at least one of whether a fluid tank cap of the fluid tank
is in place or has been removed, changes of a fluid level in the
fluid tank, changes in a fluid flow rate of the fluid of the second
system, contaminant concentration in the fluid of the second
system, or whether the second system using the fluid has been
turned on.
9. A filtration system comprising: a fluid source providing a fluid
to be filtered to a filtration line; a main filter; a secondary
filter positioned upstream of the main filter in a fluid flow
direction; a fluid quality characteristic sensor that senses a
fluid quality characteristic of the fluid; a valve positioned
upstream of the main filter and downstream of the secondary filter
in the fluid flow direction, the valve can be opened or closed so
as to switch the filtration system between a normal filtration mode
and an enhanced filtration mode, the normal filtration mode
corresponding to a first operating mode where fluid to be filtered
flows to the main filter through a first flow path from the
filtration line to a location downstream the main filter, the
enhanced filtration mode corresponding to a second operating mode
in which an increased amount of the fluid to be filtered is
filtered through the secondary filter element than when in the
normal filtration mode, the fluid to be filtered flows along a
second flow path from the filtration line through the secondary
filter prior to flowing to the location downstream the main filter,
an electronic control unit having a memory and a processor, the
electronic control unit configured to: receive a feedback signal
from the detector indicative of a change in the fluid quality
characteristic of the fluid, and switch between the normal
filtration mode and the enhanced filtration mode in response to the
change in the fluid quality characteristic.
10. The filtration system of claim 9, wherein when the filtration
system is in the normal filtration mode, no fluid to be filtered
flows through the secondary filter.
11. The filtration system of claim 9, wherein when the filtration
system is in the normal filtration mode, some fluid to be filtered
flows through the secondary filter.
12. The filtration system of claim 9, wherein the fluid quality
characteristic of the fluid is the fluid being used by a second
system, the second system being an internal combustion engine.
13. The filtration system of claim 9 wherein the fluid quality
characteristic of the fluid is the fluid being used by a second
system, the second system being a hydraulic system.
14. The filtration system of claim 9, wherein the fluid quality
characteristic is an amount of contaminant in the fluid.
15. A filtration system comprising: a fluid source providing a
fluid to be filtered; a main filter; a secondary filter; a fluid
quality characteristic sensor that senses a fluid quality
characteristic of the fluid; a valve that can be opened or closed
so as to switch the filtration system between a normal filtration
mode and an enhanced filtration mode, the enhanced filtration mode
corresponding to an operating mode in which an increased amount of
the fluid to be filtered is filtered through the secondary filter
element than when in the normal filtration mode; an electronic
control unit having a memory and a processor, the electronic
control unit configured to: receive a feedback signal from the
detector indicative of a change in the fluid quality characteristic
of the fluid, and switch between the normal filtration mode and the
enhanced filtration mode in response to the change in the fluid
quality characteristic, wherein the fluid source is a fluid tank,
and wherein the secondary filter is part of a fluid recirculating
loop that routes fluid that passes through the secondary filter
back to the fluid tank.
16. A filtration system comprising: a fluid source providing a
fluid to be filtered; a main filter; a secondary filter positioned
upstream of the main filter in a fluid flow direction; a detector
that detects a fill-up condition, a start-up condition, a change in
fluid contaminant concentration, or a fluid flow rate change of a
second system using the fluid; a pump positioned upstream of the
main filter and downstream of the secondary filter in the fluid
flow direction, the pump routes the fluid to the secondary filter
such that the pump can be activated and deactivated to switch the
filtration system between a normal filtration mode and an enhanced
filtration mode, the normal filtration mode corresponding to a
first operating mode where fluid to be filtered flows to the main
filter through a first flow path, the enhanced filtration mode
corresponding to a second operating mode in which an increased
amount of the fluid to be filtered is filtered through the
secondary filter than when in the normal filtration mode, the fluid
to be filtered flows along a second flow path through the secondary
filter prior to flowing to the main filter element; an electronic
control unit having a memory and a processor, the electronic
control unit configured to: receive a feedback signal from the
detector indicative of the fill-up event, the start-up event, the
change in fluid contaminant concentration, or the fluid flow rate
change of the second system, and, switch between the normal
filtration mode and the enhanced filtration mode in response to the
fill-up event, the start-up event, the change in fluid contaminant
concentration, or the fluid flow rate change by activating the
pump.
17. The filtration system of claim 16, wherein when the filtration
system is in the normal filtration mode, no fluid to be filtered
flows through the secondary filter.
18. The filtration system of claim 16, wherein when the filtration
system is in the normal filtration mode, some fluid to be filtered
flows through the secondary filter.
19. The filtration system of claim 16, wherein the system using the
fluid is an internal combustion engine.
20. The filtration system of claim 16, wherein the system using the
fluid is a hydraulic system.
21. A filtration system comprising: a fluid source providing a
fluid to be filtered; a main filter; a secondary filter; a detector
that detects a fill-up condition, a start-up condition, a change in
fluid contaminant concentration, or a fluid flow rate change of a
second system using the fluid; a pump that routes the fluid to the
secondary filter such that the pump can be activated and
deactivated to switch the filtration system between a normal
filtration mode and an enhanced filtration mode, the enhanced
filtration mode corresponding to an operating mode in which an
increased amount of the fluid to be filtered is filtered through
the secondary filter than when in the normal filtration mode; an
electronic control unit having a memory and a processor, the
electronic control unit configured to: receive a feedback signal
from the detector indicative of the fill-up event, the start-up
event, the change in fluid contaminant concentration, or the fluid
flow rate change of the second system, and, switch between the
normal filtration mode and the enhanced filtration mode in response
to the fill-up event, the start-up event, the change in fluid
contaminant concentration, or the fluid flow rate change by
activating the pump, wherein the fluid source is a fluid tank, and
wherein the secondary filter is part of a fluid recirculating loop
that routes fluid that passes through the secondary filter back to
the fluid tank.
22. The filtration system of claim 21, wherein the detector further
detects at least one of whether a fluid tank cap of the fluid tank
is in place or has been removed, changes of a fluid level in the
fluid tank, changes in a fluid flow rate of the fluid of the second
system, contaminant concentration in the fluid of the second
system, or whether the second system using the fluid has been
turned on.
Description
TECHNICAL FIELD
The present disclosure relates generally to filtration systems.
BACKGROUND
Internal combustion engines typically include various filtration
systems, such as air filtration systems, fuel filtration systems,
oil filtration systems, and the like. The filtration systems
generally remove contaminants, such as dust and water, from fluids
used by the internal combustion engine.
The air filtration system is part of an air intake system. The air
filtration system filters intake air prior to routing the intake
air to the engine. The air filtration systems remove dust,
moisture, and other particulate from the intake air. The air
filtration systems typically include a filter media (e.g., a
paper-based filter media, a foam-based filter media, a cotton-based
filter media, a pleated filter media, etc.) that processes the air.
Some air filtration systems include a pre-cleaner positioned
upstream of the filter media. A pre-cleaner removes at least a
portion of the dust, moisture, and other particulate matter from
the intake air prior to the intake air being processed by the
filter media. Accordingly, the pre-cleaner extends the life of the
filter media. The pre-cleaner may be an ejective pre-cleaner, a
pre-filter pre-cleaner, a cyclonic pre-cleaner, or the like. The
specific type of pre-cleaner may be selected based on the worst
dust loading conditions that an internal combustion engine is
expected to see during operation.
A pre-cleaner, however, also causes parasitic air pressure losses
in the air intake system due to the increased restriction caused by
the pre-cleaner. The parasitic losses are present even when the
pre-cleaner is unnecessary (e.g., when the internal combustion
engine is operating in a clean air environment). The parasitic
losses may cause higher pumping loss, thereby reducing the fuel
economy for the internal combustion engine (e.g., reduced miles per
gallon in a vehicle application, fewer operating hours per tank in
a generator or construction application, etc.). The reduced fuel
economy increases operating costs (i.e., increases fuel costs).
Other filtration systems, such as fuel, oil, and hydraulic fluid
filtration systems, filter liquids that are used by the internal
combustion engine or used to drive equipment. Generally, these
filtration systems draw fluid to be filtered from a tank (e.g., a
fuel tank, an oil tank, a hydraulic fluid tank, etc.). Certain
operating conditions can cause the fluid to have increased
contamination levels. Specifically, contaminant particles may be
re-entrained from the surfaces of piping, filter media, tank
bottoms, and the like during certain transient conditions, such as
fluid flow surges, vibrations, and the like. This is particularly
problematic during tank fill up and engine or hydraulic system
start up events. During tank fill ups, elevated contamination
levels may be found in the new (but frequently not clean) liquid
introduced into the tank. Contaminant levels are further increased
by the resuspension of contaminant from tank bottoms and walls by
the filling operation itself. When an engine or hydraulic system is
started, the liquid flow rate to the downstream components,
including the filtration system, goes from zero to operating flow
rates in a matter of seconds or even less. As such, extremely high
contamination levels are temporarily observed as the fluid
accelerates from a generally stationary position to a moving
stream. During these periods, wear induced damage to downstream
components is especially high. Orders of magnitude increases in
fuel contamination levels have been observed at engine start up and
during rapid changes in flow rate. Such increases in the liquid
born contamination reduce component life, reduce engine
reliability, and reduce overall system robustness. These increases
in contamination levels also have the potential to shorten the
useful life of the filtration system. Additionally, the
introduction of the multiple filter elements, much like the
above-described pre-cleaners for air filtration systems, introduces
greater restriction to the filtration systems thereby causing
parasitic liquid pressure losses in the filtration systems.
SUMMARY
One embodiment relates to an air filtration system. The air
filtration system includes a primary filter element and a
pre-cleaner positioned upstream of the primary filter element in an
air flow direction. The air filtration system further includes a
bypass valve actuatable between a first position and a second
position. When the bypass valve is in the first position, intake
air to be filtered bypasses the pre-cleaner and flows to the
primary filter element. When the bypass valve is in the second
position, intake air to be filtered is forced through the
pre-cleaner prior to flowing to the primary filter element. The air
filtration system further includes an air quality characteristic
sensor and a controller. The controller is configured to receive a
feedback signal from the air quality characteristic sensor
indicative of a sensed air quality characteristic of the intake air
and to actuate the bypass valve between the first position and the
second position via an actuation mechanism.
Another embodiment relates to a filtration system. The filtration
system includes a fluid source providing a fluid to be filtered, a
main filter, a secondary filter, and a detector that detects a
fill-up condition, a start-up condition, a change in fluid
contaminant concentration, or a fluid flow rate change of a system
using the fluid. The filtration system further includes a valve
that can be opened or closed to switch the filtration system
between a normal filtration mode and an enhanced filtration mode.
The enhanced filtration mode corresponding to an operating mode in
which an increased amount of the fluid to be filtered through the
secondary filter element than when in the normal filtration mode.
The filtration system includes an electronic control unit having a
memory and a processor. The electronic control unit is configured
to receive a feedback signal from the detector indicative of a
fill-up event, a start-up event, a change in fluid contaminant
concentration, or a fluid flow rate change, and to switch between
the normal filtration mode and the enhanced filtration mode in
response to the fill-up event, the start-up event, the change in
fluid contaminant concentration, or the fluid flow rate change.
A further embodiment relates to a method of switching a filtration
system between a normal filtration mode and an enhanced filtration
mode based on a detected event. The method includes receiving, by
an electronic control unit of the filtration system, a feedback
signal from a sensor of the filtration system. The method further
includes determining, by the electronic control unit, that the
feedback signal corresponds to a fill-up event or a start-up event.
The method includes activating, by the electronic control unit, the
enhanced filtration mode of the filtration system. The enhanced
filtration mode corresponds to an operating mode of the filtration
system in which an increased amount of the fluid to be filtered
passes through an filtration component than when in the normal
filtration mode.
Another embodiment relates to a filtration system. The filtration
system includes a fluid source providing a fluid to be filtered, a
main filter, and a secondary filter. The filtration system further
includes a fluid quality characteristic sensor that senses a fluid
quality characteristic of the fluid. The filtration system includes
a valve that can be opened or closed so as to switch the filtration
system between a normal filtration mode and an enhanced filtration
mode. The enhanced filtration mode corresponds to an operating mode
in which an increased amount of the fluid to be filtered is
filtered through the secondary filter element than when in the
normal filtration mode. The filtration system includes an
electronic control unit having a memory and a processor. The
electronic control unit is configured to receive a feedback signal
from the detector indicative of a change in the fluid quality
characteristic of the fluid, and to switch between the normal
filtration mode and the enhanced filtration mode in response to the
change in the fluid quality characteristic.
A further embodiment relates to a filtration system. The filtration
system includes a fluid source providing a fluid to be filtered, a
main filter, and a secondary filter. The filtration system includes
a detector that detects a fill-up condition, a start-up condition,
a change in fluid contaminant concentration, or a fluid flow rate
change of a system using the fluid. The filtration system further
includes a pump that routes the fluid to the secondary filter such
that the pump can be activated and deactivated to switch the
filtration system between a normal filtration mode and an enhanced
filtration mode. The enhanced filtration mode corresponds to an
operating mode in which an increased amount of the fluid to be
filtered is filtered through the secondary filter than when in the
normal filtration mode. The filtration system includes an
electronic control unit having a memory and a processor. The
electronic control unit is configured to receive a feedback signal
from the detector indicative of a fill-up event, a start-up event,
a change in fluid contaminant concentration, or a fluid flow rate
change, and to switch between the normal filtration mode and the
enhanced filtration mode in response to the fill-up event, the
start-up event, the change in fluid contaminant concentration, or
the fluid flow rate change by activating the pump.
These and other features, together with the organization and manner
of operation thereof, will become apparent from the following
detailed description when taken in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic view of an air filtration system according to
an exemplary embodiment.
FIG. 2 is a close-up schematic view of each sensor of the air
filtration system of FIG. 1.
FIG. 3 is a close-up schematic view of the bypass valve of the air
filtration system of FIG. 1.
FIG. 4 is a close-up schematic view of a bypass valve according to
an exemplary embodiment.
FIG. 5 is a block diagram of an electronic control unit according
to an example embodiment.
FIG. 6 is a flow diagram of a method of switching a filtration
system between a normal filtration mode and an enhanced filtration
mode based on a detected event according to an example
embodiment.
FIGS. 7 through 10 show, schematic views of liquid filtration
systems are shown according to example embodiments
DETAILED DESCRIPTION
Referring to generally to the figures, filtration systems having
both a normal filtration mode and an enhanced filtration mode are
shown. The normal filtration mode corresponds to an operating
condition in which fluid being filtered is routed through a primary
filtration system and bypasses a secondary filtration system. The
enhanced filtration mode corresponds to an operating condition in
which fluid to be filtered is routed through both the primary
filter and the secondary filter. The enhanced filtration mode is
used when the fluid to be filtered contains a higher than normal
level (i.e., an elevated level) of contaminants, such as water,
dust, and the like or when there is a fluid flow rate increase
(e.g., when an operator increases the throttle of an internal
combustion engine). The normal filtration mode is used when the
fluid to be filtered contains a normal level or lower than normal
level of contaminants or when fluid flow conditions are at a normal
or steady-state rate.
FIGS. 1-4 generally relate to an air filtration system. The air
filtration system filters intake air prior to routing the intake
air to an internal combustion engine. The air filtration system
includes a primary filter element comprised of a filter media
(e.g., a paper-based filter media, a foam-based filter media, a
cotton-based filter media, a pleated filter media, etc.). The air
filtration system also includes a pre-cleaner positioned upstream
of the primary filter element. The air filtration system is fitted
with a control system that includes a sensor (e.g., a dust particle
sensor, a moisture sensor, a turbidity sensor, etc.) and a flow
bypass valve mechanism that, when opened, allows intake air to
bypass the pre-cleaner and flow directly to the primary filter
element. Based on feedback from the sensor (e.g., a feedback signal
indicative of an air quality measurement, an amount of dust in the
air, an amount of moisture in the air, etc.) the bypass valve is
either opened or closed. During sensed clean air operating
conditions (e.g., low dust and moisture concentrations), the bypass
valve is opened to allow intake air to bypass the pre-cleaner,
thereby providing a low resistance air flow and better fuel
economy. During sensed dirty air operating conditions (e.g., heavy
dust or moisture concentrations), the bypass valve is closed
thereby routing intake air into the pre-cleaner to increase the
service life of the primary filter element. The overall air
filtration system provides for an overall (i.e., average) better
fuel economy rating than those systems without the bypass
valve.
FIGS. 5-9 generally relate to a liquid filtration system. The
liquid filtration system may be a fuel filtration system, an oil
filtration system, or a hydraulic fluid filtration system. The
liquid filtration systems draw fluid to be filtered from a storage
tank. The filtration system detects tank fill-ups or engine or
hydraulic system start-up events through sensors (e.g., fluid flow
sensors, fluid quality characteristic sensors, etc.) or detectors
(e.g., an ignition switch) that produce an electrical output or
signal. A controller, such as the electronic control module (ECU)
of the engine or hydraulic system, that monitors and receives the
output from the sensor or detector. When the controller receives a
signal indicating a fill-up or start-up event, the controller can
put the filtration system into an enhanced filtration operating
mode for a period of time. In some arrangements, the controller
puts the filtration system into the enhanced mode of operation when
the flow of fluid through the filtration system is elevated above a
normal fluid flow rate or is changing. While in the enhanced
filtration operating mode, the filtration system routes fluid
through additional filtering components than the normal filtration
operating mode to remove potential elevated contamination levels
from the fluid. The enhanced mode of operation continues for a time
interval determined by the controller. Alternatively, the enhanced
mode of operation continues while a fluid flow rate is changing or
elevated above a normal fluid flow rate. After the time interval
expires or the fluid flow rate through the filtration system
returns to a normal or stead-state flow rate, the filtration system
is returned to its normal mode of operation.
Referring to FIG. 1, a schematic view of an air filtration system
100 is shown according to an exemplary embodiment. The air
filtration system 100 filters intake air 102 and routes the intake
air 102 to a device, such as an internal combustion engine (e.g.,
of a vehicle, a generator, construction equipment, etc.). The air
filtration system 100 includes a primary filter element 104 housed
within a filter housing 106. The primary filter element 104 may be
a paper-based filter media, a foam-based filter media, a
cotton-based filter media, a pleated filter media, a panel filter
element, a cylindrical filter element, or another type of filter
element. The primary filter element 104 removes at least a portion
of the dust, moisture, and other particulate matter from the intake
air 102. The air filtration system 100 also includes a pre-cleaner
108 positioned upstream of the primary filter element 104 in an air
flow direction. The pre-cleaner 108 may be an ejective pre-cleaner,
a pre-filter pre-cleaner, a cyclonic pre-cleaner, or the like. When
intake air is routed through the pre-cleaner 108, the pre-cleaner
108 removes at least a portion of the dust, moisture, and other
particulate matter from the intake air 102 prior to the intake air
being processed by the primary filter element 104. When the intake
air 102 is routed through the pre-cleaner 108, the restriction of
the air filtration system 100 is higher than if the pre-cleaner 108
was not present.
The air filtration system 100 includes a bypass control system. The
bypass control system includes a bypass flow valve 110, a bypass
intake 112, a sensor 114, and a controller 202 (as shown in FIG.
2). Although shown as including two sensors 114, the air filtration
system 100 may be configured to work with a single sensor 114
(e.g., a single sensor 114 positioned upstream of a bypass valve,
which is also positioned upstream of both the pre-cleaner 110 and
the bypass intake 112). The sensor 114 measures an air quality
characteristic of intake air 102. The air quality characteristic
may relate to an amount of dust in the air, an amount of moisture
in the air, or a combination thereof. The sensors 114 may be any of
a dust particle sensor, a moisture sensor, a turbidity sensor, a
capacitance sensor, or the like. The sensors 114 provide feedback
signals indicative of the sensed air quality characteristic to a
controller 202 of the bypass control system. In some arrangements,
the controller 202 is an engine control module ("ECM") of an
internal combustion engine.
The controller 202 opens and closes the bypass flow valve 110 based
on the measured air quality characteristic (e.g., based on the
feedback signal received from the sensors 114). When the sensor
feedback indicates that the intake air 102 is clean (e.g., contains
a low level of dust and moisture), the controller 202 actuates the
bypass flow valve 110 to a first, open position creating a first
air flow path for the air filtration system 100. The first air flow
allows the intake air 102 to bypass the pre-cleaner 108 and flow to
the primary filter element 104. When the sensor feedback indicates
that the intake air 102 is dirty (e.g., contains greater than a
threshold level of dust or moisture), the controller 202 actuates
the bypass flow valve 110 to a second, closed position creating a
second air flow path for the air filtration system 100. The second
air flow path forces the intake air 102 to pass through the
pre-cleaner 108 prior to flowing to the primary filter element 104.
The second air flow path has a higher air restriction than the
first air flow path. The second air flow path increases the life of
the primary filter element 104 during dirty air conditions. It
should be understood that the flow paths of the air filtration
system 100 can be configured in an opposite manner (e.g., such that
the pre-cleaner 108 is bypassed by the intake air 102 when the
bypass flow valve 110 is closed).
Referring to FIG. 2, a close-up schematic view of each sensor 114
is shown according to an exemplary embodiment. As the intake air
102 passes through or by the each sensor 114, each sensor 114
senses the air quality characteristic. In some arrangements, the
air quality characteristic is sensed by counting and sizing
particles passing by or through each sensor 114. In other
arrangements, the air quality characteristic is sensed by measuring
an opacity or transparency of the intake air 102 by passing a light
or laser through the intake air 102. For example, the intake air
102 may pass between two parts of each sensor 114: a light emitting
part and a light sensing part. In the exemplary arrangement, the
light emitting part emits light into the light sensing part. The
opacity of the intake air 102 is determined based on how much or
how little light is sensed by the light sensing part. The opacity
of the intake air 102 corresponds to the amount of dust and
moisture in the intake air 102. In an alternative arrangement, the
air quality characteristic is sensed by measuring a moisture
content of the intake air 102. In still further arrangements, the
air quality characteristic is sensed by measuring a capacitance or
inductance of the intake air 102.
FIG. 3 shows a close-up schematic view of the bypass valve 110 of
FIG. 1. The bypass valve 110 includes a flap 302 and a hinge 304.
The hinge 304 is positioned near the bypass intake 112. The hinge
304 permits the flap 302 to pivot about the hinge 304 between a
first position and a second position. In the first position, the
flap 302 is pivoted away from the bypass intake 112 placing the
bypass valve 110 in the open position thereby permitting the intake
air 102 to travel along the first air flow path as discussed above.
In the second position, the flap 302 is pivoted towards the bypass
intake 112 placing the bypass valve 110 in the closed position
thereby forcing the intake air 102 to travel along the second air
flow path as discussed above. A valve actuation mechanism 306 moves
the flap 302 between the first position and the second position. In
some arrangements, the valve actuation mechanism 302 can maintain
the flap 302 in any position between the first position and the
second position thereby allowing at least a portion of the intake
air 102 to flow through the pre-cleaner 108 and a portion of the
intake air 102 to bypass the pre-cleaner 108. The valve actuation
mechanism 302 is controlled by the controller 202 based on the
feedback signals from the sensors 114.
FIG. 4 shows a close-up schematic view of a bypass valve 400
according to an exemplary embodiment. The bypass valve 400 is
similar to and an alternative to the bypass valve 110. For ease of
explanation, similar reference numbers and terms will be used to
describe the alternative bypass valve 400. Unlike the bypass valve
110 opening and closing a flap 302, bypass valve 400 functions by
opening and closing a plurality of louvers 402. Each of the louvers
402 includes a slat and a central hinge. The louvers 402 move
together between an opened position (when each slat is
substantially perpendicular to axis 406) and a closed position
(when each slat is substantially parallel to axis 406). When the
louvers 402 are in the opened position, intake air 102 bypasses the
pre-cleaner 108 (i.e., travels along the first air flow path as
discussed above with respect to FIGS. 1-3). When the louvers 402
are in the closed position, the intake air 102 is forced to pass
through the pre-cleaner 108 (i.e., travels along the second air
flow path as discussed above with respect to FIGS. 1-3). A valve
actuation mechanism 404 moves the louvers 402 between the opened
position and the closed position. The valve actuation mechanism 404
is controlled by the controller 202 based on the feedback signals
from the sensors 114.
The above described pre-cleaner bypass systems and methods allow
for adaptable air filtration systems having additional restriction
in pre-cleaners for better dust separation when actually separating
dust, without sacrificing restriction when handling clean air flow
through the use of a bypass valves. The systems and methods manage
unnecessary loss of pressure while flowing through pre-cleaner or
moisture removal system is avoided.
As described below in further detail, similar concepts may be
applied to other types of filtration systems, such as fuel, oil,
and hydraulic fluid filtration systems. In certain filtration
systems that filter fluid received from a tank (e.g., a fuel tank,
an oil tank, a hydraulic fluid tank, etc.), certain operating
conditions can cause the fluid to have increased contamination
levels. Specifically, contaminant particles may be re-entrained
from the surfaces of piping, filter media, tank bottoms, and the
like during fluid flow surges that can be caused by tank fill ups
and engine or hydraulic system start up events.
Referring to FIG. 5, a block diagram of an ECU 500 is shown
according to an example embodiment. The ECU 500 controls the
operation of a filtration system. Specifically, the ECU 500 toggles
the filtration system between a normal filtration mode and an
enhanced filtration mode. In the enhanced filtration operating
mode, fluid to be filtered passes through additional filtration
components than the normal filtration mode. The ECU 500 generally
includes a processor 502, memory 504, and an input/output (I/O)
506. The memory 504 includes programming modules that, when
executed by the processor 502, control the operation of the ECU
500, and thus control the operation of the filtration system.
Through the I/O 506, the ECU 500 monitors feedback signals to
determine when a fill-up and/or start-up event is detected. Fill-up
and/or start-up events can be detected by the ECU 500 by sensing
whether a fluid tank's fill cap is in place or has been removed, by
sensing changes in a liquid level in the fluid tank, by sensing
whether the internal combustion engine or hydraulic system fed by
the filtration system has been turned on (e.g., by determining a
key on situation), by sensing whether liquid flow has been
initiated through the filtration system, and/or by measuring
changes in the flow rate through the filtration system.
Accordingly, the ECU 500 can communicate with various sensors
(e.g., fluid tank cap sensors, tank fluid sensors, flow rate
sensors, engine control modules, hydraulic system control modules,
engine ignition sensors, fluid quality characteristic sensors,
etc.). Example fluid sensing techniques and systems are described
in U.S. Publication No. 2010/0327884, U.S. Publication No.
2011/0140877, and U.S. Pat. No. 4,173,893, each of which are
incorporated herein by reference in their entireties and for all
purposes. In some arrangements, it is desirable to convert an
analog output of any of the above-described sensors to a digital
output to facilitate sensor output to the ECU 500. In such
arrangements, the digital nature of the sensor feedback signals
allows the ECU 500 to be programmed to interpret the feedback
signals to distinguish insignificant changes in liquid level or
flow rate from noteworthy events, such as filling operations or
start-ups (e.g., as described in further detail below).
Through the I/O 506, the ECU 500 can actuate valves and diverters
of the filtration system to switch between the normal filtration
mode and the enhanced filtration mode. The ECU 500 switches between
the operating modes based on the feedback received from the
above-described sensors. Additionally, through the I/O 506, the ECU
500 can communicate with an operator or technician through a user
indicator (e.g., a display, an LED, a dashboard indicator,
etc.).
In some arrangements, the ECU 500 can distinguish between fill-up
events, fluid flow rate changes, and start-up events, as the
highest contaminant levels in the fluids stored in the tanks are
expected to occur during filling operations due to re-suspension of
settled contaminant (such as from the tank bottom) and the
introduction of new contaminant from the new fluid. Accordingly,
the ECU 500 can put the filtration system into the enhanced
filtration mode for a longer period of time for a fill-up event and
a shorter period of time for a system or engine start-up event. To
distinguish between the two, the ECU 500 may rely on a combination
of sensing technologies (e.g., fluid tank cap sensors, fluid
characteristic sensors, and fluid flow-rate sensors).
Alternatively, the ECU 500 can receive input from a location sensor
(e.g., a GPS transponder) to compare a location of the vehicle or
equipment with locations of known service stations or filling
terminals. If either the engine is turned on or the flow rate
increases from zero to a working flow rate while near (e.g., within
20 meters) the location of a service station, the ECU 500 can
interpret the event as a filling event. If the vehicle is not near
a service station, the ECU 500 interprets the event as a simple
start-up event.
The operation of the ECU 500 in specific systems is described in
further detail below with respect to FIGS. 6 through 10.
Referring to FIG. 6, a flow diagram of a method 600 of switching a
filtration system between a normal filtration mode and an enhanced
filtration mode based on a detected event is described according to
an example embodiment. Method 600 is performed by a filtration
system controller, such as ECU 500. In method 600, the filtration
system is normally operated in the normal filtration mode. The
filtration system can be temporarily switched into an enhanced
filtration mode based on detected events (e.g., a fill-up event or
a start-up event).
The method 600 begins when a fill-up event occurs at 602 or a
start-up event occurs at 604. A fill-up event relates to a
situation in which a tank storing liquid to be filtered by the
filtration system is filled with additional liquid. A start-up
event occurs when an internal combustion engine or hydraulic system
using the liquid filtered by the filtration system starts-up. The
fill-up event or start-up event may be determined by the
above-described sensors or detectors. For example, a fill-up event
can be determined by sensing whether the liquid tank's fill cap is
in place or has been removed or by sensing changes in the liquid
level in the tank. A start-up event can be determined by sensing or
detecting whether the engine or hydraulic system has been turned on
or by sensing whether liquid flow through the filtration system has
been initiated or is experiencing a change in the flow rate.
Feedback signals from the sensors are received at the ECU 500 at
606. Based on the feedback signals from the sensors, the ECU 500
can determine the existence of the fill-up event (that occurs at
602) or the start-up event (that occurs at 604). The ECU 500
determines whether a fill-up event occurred based on the sensor
feedback signals at 608. If a signal indicating a fill-up event is
indicated, the ECU 500 determines a duration of enhanced filtration
mode at 610. The duration of enhanced filtration mode represents
the time period for which the filtration system is in the enhanced
filtration mode before reverting back to the normal filtration
mode. In some arrangements, the duration represents an amount of
time needed to filter an amount of fluid filtered during the
enhanced filtration mode. In a further arrangement, the duration
represents an amount of time needed to remove an amount of
contaminant from the fluid or to return the fluid to a threshold
contamination level as sensed by a sensor. Still further, the
duration may represent an amount of time needed for the flow rate
of the fluid to stabilize or to return to a normal flow as measured
by a flow meter or a flow rate sensor. The duration of the enhanced
filtration mode is a relatively short term enhanced filtration
response used to reduce contamination levels in the fluid. If a
fill-up event was not detected at 608, the ECU 500 proceeds to
determine whether a start-up event occurred at 614.
If a signal indicating a start-up event is indicated, the ECU 500
determines a duration of enhanced filtration mode at 610. The
duration of enhanced filtration mode represents the time period for
which the filtration system is in the enhanced filtration mode
before reverting back to the normal filtration mode. In some
arrangements, the duration represents an amount of time needed to
filter an amount of fluid filtered during the enhanced filtration
mode. In a further arrangement, the duration represents an amount
of time needed to remove an amount of contaminant from the fluid or
to return the fluid to a threshold contamination level as sensed by
a sensor. Still further, the duration may represent an amount of
time needed for the flow rate of the fluid through the filtration
system to stabilize or to return to a normal flow as measured by a
flow meter or a flow rate sensor. In some arrangements, the
durations of enhanced filtration mode for a fill-up event and for a
start-up event are different. For example, the duration of enhanced
filtration mode may be longer for a fill-up event than for a
start-up event. The duration of the enhanced filtration mode is a
relatively short term enhanced filtration response used to reduce
contamination levels in the fluid.
In either case, if a fill-up event is detected at 608 or if a
start-up event is detected at 614, the enhanced filtration mode is
activated at 612 for the amount of time determined at 610. As
described in further detail below with respect to FIGS. 7-10, the
enhanced filtration mode can be achieved in different manners. For
example, the ECU 500 can actuate a valve that increases the flow
rate of the fluid through a kidney loop portion of the filtration
system (e.g., as shown in FIG. 7). As an additional example, the
ECU 500 can activate a diverter that diverts the fluid flow through
an additional prefilter upstream of the main filtration system
(e.g., as shown in FIG. 8). As an additional example, the ECU 500
can initiate a duplex or multiplex mode of filtration (e.g., as
shown in FIG. 9). As a further example, the ECU 500 can open and
close valves to stop fluid flow through the main filtration system
and increase flow through a kidney loop filtration system (e.g., as
shown in FIG. 10). In some arrangements, a combination of the above
enhanced filtration mode techniques is implemented by the ECU 500
for a defined duration to reduce contamination levels in the fluid
to acceptable levels.
If no fill-up event is detected at 608 and no start-up event is
detected at 614, the filtration system is set to the normal
filtration mode at 616. Likewise, if a fill-up event is detected at
608 or if a start-up event is detected at 614, the filtration
system is set to the normal filtration mode at 616 after the
determined duration (determined at 610) expires during 612. The ECU
500 continues to monitor the sensor feedback signals during
operation after the filtration system is placed in the normal
filtration mode at 616.
Referring to FIGS. 7 through 10, schematic views of liquid
filtration systems are shown according to example embodiments. Each
of the described filtration systems includes the ECU 500, a liquid
tank 702, a fill-up and/or start-up detector 704, a main filter
706, and an engine or hydraulic system 708. In some arrangements,
the main filter 706 includes a plurality of filters. In each of
FIGS. 7 through 10, thick lines indicate plumbing connecting the
tank 702 to the various components of the filtration systems, such
as the main filter 706 and the engine or hydraulic system 708.
Plumbing from the engine or hydraulic system 708 back to the tank
702 is indicated as dashed lines, which represents that this
section of plumbing exists only in arrangements where the fluid is
recirculated. For example, lubrication and hydraulic fluid is
typically recirculated, while fuel is generally burned by an
internal combustion engine. Although some fuel filtration systems
route a portion of the filtered fuel back to the tank 702. Still
referring generally to FIGS. 7 through 10, thin lines connect the
ECU 500 with the detector 704 and other components (e.g., an
actuated valve or a pump). The thin lines represent operational
electronic (e.g., hard wire or wireless) connections between these
components.
The fluid tank 702 is fitted with one or more detectors 704, such
as any of the above-described detectors. The detectors 704 may be
located in any appropriate location. In the figures, one detector
704 is shown in the bottom of the tank for illustrative purposes
only. It should be understood that detectors may be placed outside
of the tank 702 (e.g., at the tank filling cap, at the engine or
hydraulic system 708, along any of the fluid lines, etc.). Each of
the detectors 704 is operatively connected to the ECU 500 as
indicated by the black arrow. When the ECU 500 receives a feedback
signal or output indicative of a fill-up event, a start-up event, a
fluid flow change, a fluid quality characteristic, or the like, the
ECU 500 can send a signal to an actuated valve or pump to activate
an enhanced filtration mode (e.g., as described above with respect
to method 600) by opening or closing a valve or by controlling pump
speed. Typically, the ECU 500 controls the duration of the enhanced
filtration mode. The duration may be based on an amount of time
(e.g., as calculated by a timer of the ECU 500, a change in flow
rate of the fluid (e.g., as determined based on a fluid flow sensor
feedback signal), a quality of characteristic of the fluid (e.g.,
as determined by a fluid quality characteristic sensor), or a
combination thereof. The characteristics of the filters are not
described in this invention, although it is understood that the
main filter 706 is designed to reduce contamination to acceptable
levels with acceptable service life and restriction for the
application, and other filters are intended to provide performance
characteristics adequate to temporarily reduce the excessively high
contaminant concentrations found after fill-up and start-up
events.
Referring specifically to FIG. 7, a schematic view of a filtration
system 700 is shown. The filtration system 700 effectuates the
enhanced filtration mode by increasing the flow rate of the fluid
through a kidney loop filter 710. The kidney loop filter 710 is
part of a fluid recirculating loop (i.e., a kidney loop portion) of
the filtration system 700. During normal operation of the
filtration system, fluid flows continuously through the both the
kidney loop and main filtration lines when the engine or hydraulic
system 708 is running In some arrangements, however, it may be
desirable for there to be no flow in the kidney loop portion during
normal operation. At start-up and immediately upon filling the tank
702, the flow rate through the kidney loop portion, including the
kidney loop filter 710, is increased to rapidly decrease
contaminant levels in the fluid. The magnitude and duration of the
increased flow rate through the kidney loop filter 710 is governed
by application considerations, including but not limited to the
volume of the tank 702, contamination sensitivity of the downstream
components, and the residence time of fluid in the tank 702 during
the enhanced filtration mode of operation.
To switch between the enhanced filtration mode and the normal
filtration mode, the ECU 500 controls an actuated valve 712. The
actuated valve 712 may be located upstream or downstream of the
kidney loop filter 710. When the ECU 500 receives a signal or
output indicative of a fill-up or start-up event from the detector
704, the ECU 500 sends a signal to an actuated valve 712 that is
operatively connected to the ECU 500. The signal causes the
actuated valve 712 to open (or to open further) thereby reducing
the restriction in the kidney loop portion of the filtration system
700 and enabling increased flow to pass through the kidney loop
filter 710. The location where the kidney loop portion branches off
from the main filtration line may occur at any appropriate point,
but is preferably upstream of main filter 706. In some
arrangements, a pump 714 is used to further induce fluid flow
through the kidney loop portion. In such arrangements, it may not
be necessary to use the actuated valve 712 because the ECU 500 can
directly control flow rate through the kidney loop portion via the
pump 714.
Referring to FIG. 8, a schematic view of a filtration system 800 is
shown. The filtration system 800 effectuates the enhanced
filtration mode by diverting the fluid flow through an additional
prefilter 802 upstream of the main filter 706. During normal
filtration mode operation, the actuated valve 804 is open thereby
allowing fluid to continuously flow only through the main filter
706 when the engine or hydraulic system 708 is running (i.e., the
fluid bypasses the prefilter 802 during normal filtration mode
operation). At start-up and immediately upon filling the tank
(i.e., during enhanced filtration), the ECU 500 closes the actuated
valve 804 thereby forcing fluid flow through the prefilter 802
prior to passage through the main filter 706. By passing the fluid
through the prefilter 802 prior to passing the fluid through the
main filter 706, the contaminant concentration in the fluid going
to the main filter 706 is reduced, which increases the main filter
706 life and the life of downstream components. In an alternative
arrangement, a second filter is placed downstream of the main
filter 706 instead of having a prefilter placed upstream of the
main filter 706. In such an arrangement, the second filter is used
only during start-up and fill-up events in a similar manner as
described above with respect to the prefilter 802. Similar to the
filtration system 700, a pump 806 may be used to increase fluid
flow rate through the prefilter 802 and/or through the main filter
706.
Referring to FIG. 9, a schematic view of a filtration system 900 is
shown. The filtration system 900 effectuates the enhanced
filtration mode by initiating duplex or multiplex filtration.
During normal filtration mode operation, an actuated valve 902
remains closed, which forces the fluid to flow only through the
main filter 706 when the engine or hydraulic system 708 is running
At start-up and immediately upon filling the tank (i.e., during
enhanced filtration), the ECU 500 opens the actuated valve 902
thereby allowing fluid flow through both the main filter 706 and at
least one auxiliary filter 904. In some arrangements, an additional
actuated valve is positioned in fluid communication with the main
filter 706 branch. In such arrangements, it is possible to
completely divert flow through the auxiliary filter 904 such that
no fluid flows through the main filter 706. Although only one
auxiliary filter 904 is shown in FIG. 9, it should be understood
that a plurality of auxiliary filters may be employed. By diverting
at least a portion of the fluid flow through the auxiliary filter
904, the flow rate through the main filter 706 is reduced, which
also reduces loading to the main filter 706 and increases the life
of the main filter 706. Additionally, by diverting at least a
portion of the fluid flow through the auxiliary filter 904, the
overall contaminant concentrations in the fluid may be reduced to
any downstream components. The filtration system 900 permits an
alternating filter approach in which the fluid flow during normal
operation could be directed through either the main filter 706 or
the auxiliary filter 904. That is one of the main filter 706 and
the auxiliary filter 904 could be used as the "main filter" for a
first period of time, and the other of the main filter 706 and the
auxiliary filter 904 could be used as the "main filter" for a
second period of time. This alternating filter approach enables
balanced loading of the main filter 706 and the auxiliary filter
904, which advantageously allows the two filters to be serviced at
the same time rather than replacing one filter sooner than the
other filter. Similar to the filtration systems 700 and 800, a pump
906 may be used to increase fluid flow rate through the main filter
706 and the auxiliary filter 904.
Referring to FIG. 10, a filtration system 1000 is shown. The
filtration system 1000 is similar to the filtration system 700.
Accordingly, like numbering is used with respect to the filtration
systems 1000 and 700. The sole difference between the filtration
system 1000 and the filtration system 700 is the position of the
actuated valve 712, which is described in further detail below.
Similar to the filtration system 700, the filtration system 1000
effectuates the enhanced filtration mode by routing fluid through a
kidney loop portion of the filtration system 1000 that includes the
kidney loop filter 710. During normal operation of the filtration
system 1000, the actuated valve 712 is open permitting fluid flow
through the main filter 706 and to the engine or hydraulic system
708. Following fill-up or start-up events detected by the ECU 500
based on feedback from the detector 704, the ECU 500 sends an
output to the actuated valve 712 to fully or partially close the
actuated valve 712, which temporarily increases the fluid flow
through the kidney loop filter 710. Thus, the main filter 706 and
any downstream components do not see total contamination load per
unit time despite the elevated contaminant concentrations, and the
main filter 706 and downstream components are protected from any
spikes in contaminant concentration of the liquid thereby
increasing their lives, increasing equipment reliability, and
increasing system robustness.
As discussed above, the filtration system 1000 can enter the
enhanced filtration mode with the actuated valve 712 fully closed
or partially open. In arrangements where the actuated valve 712 is
fully closed, fluid flow through the main filter 706, and thus to
the engine or hydraulic system 708, is cut off. Accordingly, this
option is only practical if actual operation of the equipment using
the engine or hydraulic system 708 can be delayed until the fluid
is cleaned. In other arrangements, the actuated valve 712 remains
partially open following fill-up or start-up events to enable a
small amount of the fluid to pass through to the main filter 706
and on to the engine or hydraulic system 708 to enable minimal
operation of the engine or hydraulic system 708 (e.g., engine
idling) to occur during the time that the fluid is being cleaned by
the kidney loop filter 710.
Regardless of the particular filtration system used, the enhanced
filtration mode is implemented by the ECU 500 immediately after
detection of a fill-up event, a start-up event, another transient
event (e.g., events that cause changes in fluid flow rate through
the filtration system), and upon start-up or initiation of fluid
flow from the tank 702. The enhanced filtration mode is continued
temporarily until one or more of the following conditions occurs
(1) until a predetermined time has elapsed, (2) until a
predetermined volume of fluid has been filtered, (3) until
contamination levels in the fluid have dropped to acceptable levels
as determined by an actual or virtual contamination sensor, (4)
until the flow rate of fluid through he filtration system has
stabilized for a defined period of time, or (5) when the flow rate
of fluid through the filtration system has returned to a normal
flow rate. Once one or more of the above-noted conditions is
achieved, the ECU 500 sends an appropriate output signal to return
the system to its normal or typical operating mode or condition. In
arrangements where the enhanced filtration mode stops after a
predetermined time has elapsed, the predetermined time may be
calculated as a function of the residence time of the fluid during
operation in the enhanced filtration mode. Normally, the
predetermined time should be at least three times the residence
time. In arrangements where the enhanced filtration mode stops
after a predetermined volume of fluid has been filtered, the
predetermined volume is typically a function of the tank 702
volume. Normally, the predetermined volume to be filtered during
the enhanced filtration mode should be at least three times the
tank volume. In arrangements where the enhanced filtration mode
stops after contamination levels of the fluid have been reduced to
an acceptable level, a contamination sensor, such as a portable
particle counter or other type of contamination sensor, can be
fluidly connected to the system (e.g., immediately downstream of
the tank 702) and electronically connected to the ECU 500 to
provide an output signal indicative of the contaminant
concentration. When the contamination reaches an acceptable level
of cleanliness, such as an ISO 4406 code of 18/16/13 in fuel as
measured using a portable particle sensor, the ECU 500 then outputs
a signal to discontinue enhanced filtration mode.
As previously mentioned, in some arrangements it is desirable to
distinguish between fill-up and start-up events, as contamination
levels are likely to be higher after fill-up events. In response to
determining different events, different enhanced filtration modes
can be implemented by the ECU 500 depending on the type of event.
For example, one (or more) of the enhanced filtering modes can be
used in response to start-up events for a first time period or
volume of fluid filtered, and the same enhanced filtering modes can
be used in response to fill-up events for a longer period of time
or a greater volume of fluid filtered. For example, if a period of
time of three minutes is used for start-up events, a period of time
of six minutes or longer can be used for fill-up events. The
above-described enhanced filtration modes can also be applied in
response to other detected events, such as events that cause fluid
flow surges (e.g., as occur when depressing the accelerator). For
example, the enhanced filtration mode can be used in response to
rapidly changing fluid flow rates and continue for a period of time
(e.g., three minutes) after the flow rate stabilizes. In such
arrangements, the enhanced filtering mode may be implemented for a
different time period or volume of fluid filtered than for fill-up
or start-up events.
The above-described filtration systems 700, 800, 900, and 1000 are
described with respect to providing fluid to an engine or hydraulic
system 708. However, it should be appreciated that the enhanced
filtration modes described in the filtration systems 700, 800, 900,
and 1000 can also be applied to bulk storage tanks for fluid or
other applications not directly attached to an engine or hydraulic
system. For example, by removing eliminating the engine or
hydraulic system 708 in any of the in any of the filtration systems
700, 800, 900, or 1000, the resultant system can be used with bulk
storage or dispensing tanks in which the fluid from the main filter
706 is recirculated and/or dispensed.
As utilized herein, the terms "approximately," "about,"
"substantially," and similar terms are intended to have a broad
meaning in harmony with the common and accepted usage by those of
ordinary skill in the art to which the subject matter of this
disclosure pertains. It should be understood by those of skill in
the art who review this disclosure that these terms are intended to
allow a description of certain features described and claimed
without restricting the scope of these features to the precise
numerical ranges provided. Accordingly, these terms should be
interpreted as indicating that insubstantial or inconsequential
modifications or alterations of the subject matter described and
claimed are considered to be within the scope of the invention as
recited in the appended claims.
It should be noted that the term "exemplary" or "example" as used
herein to describe various embodiments is intended to indicate that
such embodiments are possible examples, representations, and/or
illustrations of possible embodiments (and such term is not
intended to connote that such embodiments are necessarily
extraordinary or superlative examples).
It is important to note that the construction and arrangement of
the various exemplary embodiments are illustrative only. Although
only a few embodiments have been described in detail in this
disclosure, those skilled in the art who review this disclosure
will readily appreciate that many modifications are possible (e.g.,
variations in sizes, dimensions, structures, shapes and proportions
of the various elements, values of parameters, mounting
arrangements, use of materials, colors, orientations, etc.) without
materially departing from the novel teachings and advantages of the
subject matter described herein. For example, elements shown as
integrally formed may be constructed of multiple parts or elements,
the position of elements may be reversed or otherwise varied, and
the nature or number of discrete elements or positions may be
altered or varied. The order or sequence of any process or method
steps may be varied or re-sequenced according to alternative
embodiments. Other substitutions, modifications, changes and
omissions may also be made in the design, operating conditions and
arrangement of the various exemplary embodiments without departing
from the scope of the present invention.
* * * * *
References